Proceedings Wednesday 13th April by HELLI

Table of Contents, Wednesday 13th April th Heavy Lifting in 2,500 m water depth, Henk de Boo van Uijen, Design, construction and commissioning of a heavy lift offshore crane, Arjo van Putten, Flexible load handling solutions for multi purpose vessels, Tønnes Seierstad

Wednesday 13 April

Page 3 Page 27 Page 76

New risk based bolt maintenance procedures – improved reliability/reduced life cost of offshore cranes, Rod Corbett Special engineered bolts for critical joints in the lifting industry, Ragnar Sandve Lifting and handling remote monitoring and diagnostic solutions, Aaron J. Spak W A RFID inspection system the new Crosby Quic ‐ Check, inspection and identification system , Frédéric Crynen Temporary lifting facilities for the BP Magnus crane replacement, Gordon Mccombie

Page 95 Page 120 Page 143 Page 169 Page 192

Mob‐boat handling with offshore cranes – combination of design parameter Tor Raknestangen Training & competence in crane transfer operations; the importance of being prepared, David Brittan Lifting persons with carriers suspended from offshore cranes application of European commission guidance document, Gunnar Matre

Page 227

Reception given by the municipality of Stavanger in the Stavanger Maritime Museum Local beer tasting program with small tapas

Page 324

Page 246 Page 297

Program part one Wednesday 13th April Morning session Chair: Stephen Werhle Headline: Heavy Lifting 08:30 Heavy Lifting in 2,500 m water depth, Henk de Boo van Uijen, 09:00 Design, construction and commissioning of a heavy lift offshore crane, Arjo van Putten 09:30 Flexible load handling solutions for multi purpose vessels, Tønnes Seierstad Headline: Operational Maintenance & Inspection 10:00 New risk based bolt maintenance procedures – improved reliability/reduced life cost of offshore cranes, Rod Corbett 10:30 Coffee / CraneExpo 11:00 Special engineered bolts for critical joints in the lifting industry, Ragnar Sandve 11:30 Lifting and handling remote monitoring and diagnostic solutions, Aaron J. Spak W 12:00 Lunch / crane expo

Speaker

Henk de Boo van Uijen,Jumbo Offshore, NL Lecture: Heavy Lifting in 2,500 m water depth‐ Cascade & Chinook FSHR Installation Background:He has a bachelor degree in Mechanical Engineering and has more than 20 years experience in the marine heavy lift, transport and installation industry. Prepared preliminary, principal and detailed engineering for all kinds of lifting operations, raised method statements, risk assessments etc

Heavy lifting in 2,500 m water depth Cascade & Chinook FSHR Installation

Henk de Boo van Uijen – Manager Offshore Engineering Jumbo Offshore 13 April 2011 – Stavanger

Cascade & Chinook TSFK presentation Heavy lifting in 2,500 m water depth – Cascade & Chinook FSHR installation •

Jumbo Offshore

•

Cascade & Chinook project details

•

Project execution phase: – Mobilisation – Loading and transportation – Offshore operations

•

Project specific challenges

13 April 2011 – Stavanger

Jumbo Offshore

•

Jumbo is a privately owned company

•

Jumbo employs over 450 people worldwide

•

Jumbo operates a fleet of 13 Heavy Lift Vessels

•

Jumbo has > 40 years of experience in heavy lift shipping

•

In-house new building department

•

Evolution lift capacity from 100 Te to 1.800 Te

13 April 2011 – Stavanger

Jumbo Offshore - vessels •

Huisman Mast Cranes 900 Te at 25 m

•

Dual crane configuration

•

Re-reeving to various configurations

13 April 2011 – Stavanger

Jumbo Offshore - vessels A new patented Deepwater Deployment System, installed September 2009: 1000 t at 1000 m Depth

13 April 2011 â&#x20AC;&#x201C; Stavanger

Cascade & Chinook Project - General

FSHR

Water Depth : 2515 – 2744 m 13 April 2011 – Stavanger

Cascade & Chinook Project - General •

•

Client: Technip Houston, USA – (main contractor) Ultimate Client: Petrobras Americas, USA

•

Mobilise Project Equipment in Rotterdam (The Netherlands)

• • • • •

Load 5 B-Cans in Pori (Finland) Set-up in field Construction of Riser by Deep Blue Hand-over 410 Te riser to Fairplayer Dual crane shift 350 Te B-Can and connect to Riser

•

Lift B-Can/Riser Assembly (760 Te) and lower to 200 m water depth

•

Connection to bottom anchor at -2500 m by Technip

• 13 April 2011 – Stavanger

Demobilise in Pascagoula

Cascade & Chinook Project – Jumbo Scope •

Provision of vessel related engineering: – Vessel Stability and Motion Analysis – Assistance with design of Hang-Off Frame – Engineering for loading, shipment & overboarding of BC’s – Subsea installation engineering by Technip

•

Lifting Operations

–

Overboard B-Can/Riser assembly, up-end BCan and lower assembly to - 200 m water depth

 Pull in of Riser at - 2500 m by Technip

13 April 2011 – Stavanger

Mobilisation Rotterdam

• •

Install Hang-Off Frame

• •

Install and test 2 Deepwater Winches

• • •

Install anti twist system

Re-reeve cranes to 14-fall configuration (800 Te SWL each) with Deepwater Deployment System

Install accommodation + facilities for additional crew

Install Crane Tip Monitoring System Misc. Installation Aids

13 April 2011 – Stavanger

Loading Buoyancy Cans – Finland •

Loading 5 B-Cans at Technip yard in Pori, Finland

•

350 Te, 6.4 m dia, 38 m length

•

Fibre grommets were used for lifting (same as for Offshore use)

•

2 B-Cans in the lower hold + 3 on deck

13 April 2011 – Stavanger

Transport Buoyancy Cans Transport from Pori (Finland) to offshore location Gulf of Mexico (18 days)

13 April 2011 â&#x20AC;&#x201C; Stavanger

Construction of Riser Technip Deep Blue – deepwater construction vessel

410 Te riser through moonpool

13 April 2011 – Stavanger

Wet Handshake of Riser With forward crane of Fairplayer

13 April 2011 â&#x20AC;&#x201C; Stavanger

Wet Handshake of Riser and hang off

13 April 2011 â&#x20AC;&#x201C; Stavanger

Connect Riser to Buoyancy Can

Connection made on deck Fairplayer

13 April 2011 â&#x20AC;&#x201C; Stavanger

Lift and Overboard B-Can + Riser Lifting and overboarding of the complete system (B-Can + Riser)

13 April 2011 â&#x20AC;&#x201C; Stavanger

Lift and Overboard B-Can + Riser

13 April 2011 â&#x20AC;&#x201C; Stavanger

Lift and Overboard B-Can + Riser Upending of the Buoyancy Can, load transfer from forward crane to aft crane

13 April 2011 â&#x20AC;&#x201C; Stavanger

Lift and Overboard B-Can + Riser Lowering through splashzone and completion of upending

13 April 2011 â&#x20AC;&#x201C; Stavanger

Lowering B-Can + Riser •

Connect orientation rigging, disconnect forward crane

•

Lowering by Jumbo’s Crane – subsea operations performed by Technip’s Offshore Construction Vessel Deep Pioneer

•

Connection of Riser to seabed by Deep Pioneer

•

Once connected, Jumbo’s crane block disconnected from the B-Can by Technip ROV

•

Final Pull-Down by Deep Pioneer

13 April 2011 – Stavanger

Cascade & Chinook project movie

Jumbo Cascade project movie - 2 mins

13 April 2011 â&#x20AC;&#x201C; Stavanger

Project Specific Challenges • • • • • • •

•

First time usage of Deepwater Deployment System 760 tonnes offshore dual crane lift with Jumbo vessel Hang-off frame design Subsea hand over 5 long Risers Lifting B-Cans from the HLV hold to launching position on deck Predicting the full dynamic loading of Jumbo’s cranes with the 2300m FSHR suspended subsea. Planning and designing the systems with sufficient redundancy to cope with the lengthy operations and limited available weather windows. SIMOPS: Accurate positioning of the Heavy Lift vessel as well as working closely to Technips installation vessels during the installation at 2,500m water depth and in close proximity to subsea infrastructure. Integrating strengths of two offshore contractors to make the project to a success.

13 April 2011 – Stavanger

Cascade & Chinook Project

THANK YOU FOR YOUR ATTENTION

13 April 2011 – Stavanger

Speaker

Arjo van Putten, GustoMSC, NL Lecture: The design, construction and commissioning of a heavy lift offshore crane Background: Graduated at Delft University in 1998 at Mechanical Engineering. Employed at GustoMSC in Schiedam (Netherlands) since April 2007.

The design, construction and commissioning of a heavy lift offshore crane

Stavanger, 13 March 2011

Presentation 1. 2. 3. 4. 5. 6.

Introduction offshore crane 5000 T Crane characteristics Engineering - Boom Fabrication - Main hook Installation - A-frame Commissioning and testing

page 2

Introduction offshore crane

page 3

Introduction offshore crane

A-frame Main block

Boom

2. Bogie system

3. Slewing platform

Revolving Vessel fixed

1. Tubcollar page 4

Introduction offshore crane

ď&#x201A;§ Diameter: 28 meter, weight: ~ 600 ton including part of tub ď&#x201A;§ Toothrack basis for revolving, upper rail for bogies page 5

Introduction offshore crane

 Front bogie wheels: 2 x 8  Aft bogie wheels: 2 x 4  Counter bogie wheels: 2 x 4 page 6

Introduction offshore crane

ď&#x201A;§ Front bogie wheels: 2 x 8

Introduction offshore crane

page 8

5000 T crane characteristics     

Fully electric 360 deg revolving crane Main hoist SWL of 5000t and Auxiliary hoist 1 of 800t Simultaneous use of main hoist and auxiliary 1 for tilting jackets COG of crane in slewing center with empty boom at 60⁰ To pass Bosporus bridge; lowering A-frame

page 9

5000 T crane characteristics     

Lifting height Main Hoist: ~ 100 m Lifting height Whip Hoist: ~ 135 m Short minimum radius on aft side Maximum radius: 110 t @ 118 m with whip hoist With auxiliary 1 hoist 500 t @ 114 m

page 10

5000 T crane characteristics Ship  Designed by GustoMSC  Special hull shape for dual draft transit speed / stability  DP3  Length: 183 m  Width: 47 m

page 11

5000 T crane characteristics

GustoMSC building 12 floors high

page 12

Crane design â&#x20AC;&#x201C; Y-shaped boom

A-frame Main block

Boom

2. Bogie system

3. Slewing platform

Revolving Vessel fixed

1. Tubcollar page 13

Crane design – Y-shaped boom Main aspects:  Reduce weight  Reduce complexity  Trolley hoist integration

page 14

Crane design â&#x20AC;&#x201C; Y-shaped boom Difference mainly in the lower part: ď&#x201A;§ 4 chords instead of 8

page 15

Crane design – Y-shaped boom Y-shaped boom versus A-shaped boom:  Weight reduction  No support structure for trolley hoist, 5th chord!  Reduced number of joints, less complex  Top part similar  Y-shape not traditional for lattice tubular boom BUT:  Strength?  (Lateral) stiffness?  Dynamic behaviour?

page 16

Crane design â&#x20AC;&#x201C; Y-shaped boom Strength lattice structure

page 17

Crane design â&#x20AC;&#x201C; Y-shaped boom Strength boom head

page 18

CRANE DESIGN – Y SHAPED BOOM Eigen modes

 Natural frequency below minimum wave period page 19

Crane design â&#x20AC;&#x201C; Y-shaped boom Dynamic behavior â&#x20AC;&#x201C; superposition eigen modes

page 20

Crane design â&#x20AC;&#x201C; Y-shaped boom Y-shape boom at construction yard

page 21

Fabrication – Main hook

Main aspects:  Size and weight  Capable fabricators in EU  Extensive fabrication process

page 22

Fabrication â&#x20AC;&#x201C; Main hook Complete main lower block

page 23

Fabrication – Main hook Starting points:  Four prong hook  5000 T in 2 prongs @ 45 deg  Up to 2x250 mm slings on each prong

Fabrication :  Weight 37 ton  Size 3.6 m x 3.6 m x 2.0 m  Casting  Fabrication period: > 4 months

page 24

Fabrication – Main hook Steel out-of furnace into transport can

 Monitoring temperature  Monitor steel composition – adding elements page 25

Fabrication â&#x20AC;&#x201C; Main hook Pouring steel from transport can in cast

page 26

Fabrication – Main hook Cool down - 1 month After cool-down:  Heat treatment to achieve mechanical properties  Material testing  Machining

page 27

Fabrication â&#x20AC;&#x201C; Main hook

page 28

Installation – A-frame Main aspects:  Double hinged structure  Lifting height  Aft leg in two parts  Tolerances

page 29

Installation â&#x20AC;&#x201C; A-frame A-frame terminology Top hinge Front leg

Upper part aft leg

Aft leg hinge

Lower part aft legs page 30

Installation â&#x20AC;&#x201C; A-frame

page 31

Installation â&#x20AC;&#x201C; A-frame

page 32

Installation â&#x20AC;&#x201C; A-frame

page 33

Installation â&#x20AC;&#x201C; A-frame

page 34

Installation â&#x20AC;&#x201C; A-frame

page 35

Installation â&#x20AC;&#x201C; A-frame

page 36

Installation â&#x20AC;&#x201C; A-frame

page 37

Installation â&#x20AC;&#x201C; A-frame

page 38

Installation â&#x20AC;&#x201C; A-frame

page 39

Installation â&#x20AC;&#x201C; A-frame

page 40

Installation â&#x20AC;&#x201C; A-frame

page 41

Commissioning and testing Commissioning of all systems:  Winches  PLC system / HMI interface / LMS system  Slewing drives  HVAC  Pneumatic and hydraulic systems

page 42

Commissioning and testing (Overload)Testing of the crane:  Tuggerwinches  All hoist winches at the maxima of the load curves  Calibration of LMS

page 43

Commissioning and testing 550t @114m overload test auxiliary 1

page 44

Commissioning and testing 5000t @ 32m test of main

page 45

Commissioning and testing

page 46

Commissioning and testing

page 47

Your partner

www.GustoMSC.com

Speaker

Tønnes Seierstad, National Oilwell Varco, NO Lecture: Flexible load handling solutions for multi purpose vessels Background: He joined NOV (former Hydralift) as a Project Engineer in 1996 after working in the offshore industry since receiving his B.Sc. in Mechanical Engineering/Marine Technology from University of Agder, Norway in 1988.

Lifting and Handling Solutions

Flexible load handling solutions for multi purpose vessels The 16th North Sea OFFSHORE CRANES & LIFTING CONFERENCE Tønnes Seierstad Sales Manager Cranes & Winches National Oilwell Varco

One company … unlimited solutions

76460355

NOV - Company Overview Company at a Glance

NOV

•Employees

40,000

•Market Capitalization $ 33.1 B •Revenue 2009

$ 12.1 B

•Countries represented: 50+ •# of facilities:

700+

•# of service personnel 1700+ •# of engineers

National Oilwell Varco is a worldwide leader in the design, manufacture and sale of equipment and components used in oil and gas drilling and production, the provision of oilfield inspection and other services, and supply chain integration services to the upstream oil and gas industry. One company … unlimited solutions

3500+

Lifting and Handling

•NYSE

Drillships and Semi-submersibles delivered from Korean Yards with NOV Equipment

Lifting and Handling

Are you ready to assist? One company â&#x20AC;Ś unlimited solutions

Flexibility? Versatile system Lifting and Handling

One company â&#x20AC;Ś unlimited solutions

How to be flexible? Prepare: For Newbuilds and major upgrades:  Cooperation Operator, Designer and Supplier  Prepare for the future – think ahead  SWL and operating     

depth spare capacity Full hoisting height with AHC on both winches 2 pcs AHC Cranes Multiple Winches (under deck) – alternative routing / tandem lift Knuckle Boom Special Lift Mode Fiber Rope Extension System

One company … unlimited solutions

Lifting and Handling

 Examples:

How to be flexible? Mix these: 



Well Intervention Systems



Cable Lay Equipment



Pipe Lay Systems

    

One company … unlimited solutions

Lifting and Handling



Offshore Subsea Cranes and Winches – Active Heave Compensation (AHC) Heavylift cranes and shipboard deck cranes Fiber Rope Extension Systems Deep Water Lowering Systems A-Frames Electric Anchor Handling Winches with Loadlim™- AHC options Electric Secondary Winches

Flexible solutions Aker Wayfarer –400t & 50t NOV AHC Cranes

Lifting and Handling

Photo: www.valderhaug.no One company … unlimited solutions

Flexible solutions Far Samson –250t NOV AHC Crane–315t / 250t AHC Winches

Lifting and Handling

Photo: www.valderhaug.no One company … unlimited solutions

Flexible solutions Well Intervention Vessels  Well Intervention Tower with all required equipment  Main lifting system with AHC  Auxiliary Winches  Pipehandling systems  Top drive    

(top hole drilling) Moonpool systems Skidding systems AHC Crane Integrated HPU for Tower equipment and AHC Crane

One company … unlimited solutions

Lifting and Handling

 Guide-/Podline system with AHC

Flexible solutions Skandi Akerâ&#x20AC;&#x201C;400t NOV AHC Crane & 450t Well Intervention System

Lifting and Handling

One company â&#x20AC;Ś unlimited solutions

Flexible solutions Larger Anchor Handling Vessels  Electric Anchor Handling Winch with Loadlim(Pat)

One company … unlimited solutions

Lifting and Handling

- Reduced CO2 emission and vessel fuel consumption  Turning your AHTS vessel into a construction vessel - Winch approved for lifting with AHC - Regeneration of energy in AHC operation - Reduced installed power requirement (peak power)

Flexible solutions

Lifting and Handling

One company â&#x20AC;Ś unlimited solutions

Flexible solutions Pipe / Cable lay systems  Deck-mounted add-on systems

One company … unlimited solutions

Lifting and Handling

for existing OCV’s  Complete systems:  Under-deck or above-deck Carousels / reels  Tensioners  Over-boarding systems  Ramps & towers  Aligners  A&R Winches  Plough handling systems

Flexible solutions – NOV FRES

Lifting and Handling

One company … unlimited solutions

Flexible solutions – 800mT DWLS  NOV Main Crane  3000T Post Crane

 NOV AHC Winch  800T – 1000m

One company … unlimited solutions

Lifting and Handling

 NOV FRES  800T – 3000m

Flexible solutions â&#x20AC;&#x201C; Triple crane

Lifting and Handling

One company â&#x20AC;Ś unlimited solutions

Flexibility on existing equipment

One company … unlimited solutions

Lifting and Handling

Extend the operational capacities of your existing equipment:  Fiber Rope Extension Systems (FRES)  Active Heave Compensation  New winch with more wire / higher SWL  Upgrade Hydraulic Power Unit – Higher speed  Upgrade Crane Control System - ASOPS (Automatic Subsea Overload Protection System) - Splash Zone Mode - Logging System -Wire Wear Estimator (WWE)

Lifting and Handling Solutions

Thank you for your attention! Questions?

One company â&#x20AC;Ś unlimited solutions

Speaker

Rod Corbett, RotaBolt Ltd, UK Lecture: New risk based bolt maintenance procedures – improved reliability/reduced life cost of offshore cranes Background: He is a fastener specialist and metallurgist having worked in the ‘Bolt’ business for the majority of his career. Experience covers manufacturing, design, application engineering and tightening of bolts and joints. This experience has been gained initially in aerospace, automotive, motor sport and defence and then for the last twenty years in power generation, petrochemical, mining, oil and gas industries.

The 16th North Sea

Offshore Cranes &Lifting Conference

KRANTEKNISK FORENING NORWEGIAN SOCIETY OF LIFTING TECHNOLOGY

Mandatory Bolt Checking Cost Effective Options

Rod Corbett RotaBolt

Mandatory Bolt Checks

Slew bearing Fatigue

Corrosion

Boom

Loosening A Frame

Re-tightening

Bolted Joint Reliability Design Component Quality

Maintenance Free

Installed Bolt Tension Joint compression

Design Tension versus fatigue Design Tension FMmin

Working Load FA

Fatigue on bolt ÂąĎ&#x192;a

Design tension versus transverse shake

Friction Grip

20-50% Up to 5 years

NDT crack detect

10-20% per annum

Corrosion visual

Bolt removal

Bolt Checks Local Surveyor Tightness ??

retighten

Tensioner Break out

Technology Driven

Tension Measure

Corrosion ??

Anomalies/mismatch Design Tension

Crack Detect

Corrosion Protection

Corrosion Check

Bolt Spec

Elastic Strength

Installation

Tension Control

Design

Tightening Feasibility

UTS 1030 MPa

0.2%PS 940 A

HT O/Load 846 EL 830

LOAD

A LOAD

Bolt A = Elastic Limit B = 0.2% Yield Stress

0.2%

658

A = Elastic Limit B = 0.2% Yield Stress

0.2%

ELONGATION

ISO 898 10.9 Tensile Capacity

Hydraulic Tensioners Bolt Load = Pressure x area

Load Transfer Relaxation

Hydraulic Overload Load Transfer Compensation

O v e r lo a d F a c to r in r e la tio n to B o lt D im e n s io n s 1 .4 5 1 .4

Overload Factor

1 .3 5 1 .3 1 .2 5 1 .2 1 .1 5 1 .1 1 .0 5 1 Residual Design Tension 1 Based on estimate

L e n g t h : D ia m e t e r R a t io

Tensioner Accuracy Research B

HT O/Load 846

90 2.1/4 x 29 in 4340 studs LOAD

A = Elastic Limit B = 0.2% Yield Stress

O/Load LOAD

1.28

Bolt 658

A = Elastic Limit B = 0.2% Yield Stress

Overload to 79% yield 0.2%

0.2%

ELONGATION

ELONGATION Effective overload 1.09 â&#x20AC;&#x201C; 1.76

Slew Ring Bearing bolt design VDI 2230

FMmin = (1- â&#x2C6;&#x2026;)FA + FKreq + FZ FMmax = FMmin x aa

Hydraulic Tensioner

Torque

Tension Control

Mind Set 1.2

Actual 1.6

Mind Set 1.6

Actual 2.0

aa 1.1

Advanced Tension Control System

Corrosion Galvanic Protection

Noble

Carbon Gold Silver

Titanium Nickel alloy St Steels Steel Aluminium Zinc/Cadmium

Sacrificial

PTFE

PTFE Poor Adhesion

PTFE Coating 2 years

New Coatings

Xylar 1

AL Ceramic 520C, 20 micron

U/size Bolt

Zinc Nickel EP

Zinc Nickel EP 25 micron plus

Un Proven

DeltaTone Zinc Flake Automotive 30 years

Wind Turbines 10 years 1000 hrs Salt Spray

Electroless Nickel

Galvanic Series Noble

Carbon Gold Silver

Titanium Nickel alloy St Steels Steel Aluminium Zinc/Cadmium

Sacrificial

Electroless Nickel

12-17 yrs Drilling Rigs

No Corrosion

Shell Brent Subsea Clamps

Coastal Refineries High Temperature

Future Cost Effective Bolt Checking

Design Tension

No Fatigue No loosening

Bolt removal

Corrosion protection

No corrosion long term

Speaker

Speaker: Ragnar Sandve, Bolt Norge as, NO Lecture: Special engineered bolts for critical joints in the lifting industry Background: Degree as an Aeronautical Engineer Extended with Aviation Maintenance Management program and various positions within Aviation Maintenance management and Marketing & Sales Maintenance Management within oil service companies Managing Director of Bolt Norge AS

Special engineered bolts for critical joints in the lifting industry Ragnar Sandve, CEO Bolt Norge Arne Aarre, Co-author, inventor & founder

Scedule : : : : : : : : :

Who we are Challenges in joint design What did we do? Film Why do they still engineer the same problem? 3D-animations What is Bondura? Summary Questions

Who we are : Bolt Norge established 1986 : Developed and patented Bondura pin : Engineering and production in Bryne : Production in the US

Challenge

Result

Solution

Fill the gap!

What did we do?

Film

Why do they still design/engineer in the same problems today?

Technology is not known widely enough! Our goal: : Bondura becoming the new industry standard for critical joints. - Heavy loads - High precision

3D-animations

“….trialed these expandable coned pins on the G1 PHM pivot arms back in 2003” “…. would wear out in a few years and require frequent weld and machining repairs” “…. to the G1 in late 2008 I inspected this common wear connection and found “ “…. the bondura bolts to be as tight as the day it left the shop in 2003.” Dean Young Program Manager - Top Drive & Pipehandling Transocean

Summary : : : : : :

Problem is introduced during design Becomes a safety issue over time Is it worth it? There is a solution Use it for your safety New industry standard

Bilde sluttsekvens film Questions!

Speaker

Speaker: Aaron J Spak, Impact‐RLW Systems Lecture: Lifting and handling remote monitoring and diagnostic solutions Background: Mr. Spak has been managing hardware, software, and system development programs at Impact‐RLW for the past 6 years and holds a B.S. and M.S. in Mechanical Engineering from Bucknell University in Lewisburg, PA USA.

Lifting and Handling Remote Monitoring Solutions Aaron J. Spak, Manager, Technology Deployment 13 April 2011 16th Annual North Sea Offshore Cranes and Lifting Conference, Stavanger, Norway

www.impact-rlw.com

Agenda • Impact-RLW Systems Introduction • Condition Based Maintenance • Monitoring Technologies as Part of a Comprehensive CBM Strategy • Remote Monitoring Design Considerations Objectives 1) Present overall approach for implementing remote monitoring systems as part of an overall Health Management system. 2) Share case study of implementation on Lifting and Handling equipment. www.impact-rlw.com

Impact Technologies What Does Impact Do? • Engineer and implement advanced health management solutions that monitor, detect, isolate, and predict equipment performance and readiness • Software solutions, smart sensors and hardware solutions, full system designs • Development, test and evaluation, integration, and deployment expertise

• Integrate with operator, maintenance, and logistics systems to minimize life cycle costs while maximizing system availability

www.impact-rlw.com

Impact Core Business Areas

www.impact-rlw.com

Condition Monitoring Terminology •

Condition Based Maintenance (CBM): A philosophy of maintaining equipment based on an estimation of its condition and maintenance logistics. Enhanced application of CBM is through the prediction (prognosis) of the equipment remaining useful life or time to service need.

•

Prognostics and Health Management (PHM): A health management approach to reduce or eliminate inspections and timebased maintenance through accurate monitoring, incipient fault detection, and prediction of impending failure.

www.impact-rlw.com

Preventive

Condition Based

ce an en t nt s ai Co M

Cost

CBM/PHM Cost Benefit

Total Cost

Corrective

ing or Operat nce a Perform Cost

Number of of Faiure Events Number Failure Events

www.impact-rlw.com

Cost Chart Adapted from “Machinery Oil Analysis - Methods, Automation & Benefits”, Larry Toms, p. 23, 1995.

Condition Based Maintenance Benefit • • •

Optimize maintenance based on objective evidence Real-time visibility into asset operations/utilization Facilitate long-range re-capitalization planning

Prognostics Health Management Condition Based Maintenance Usage-based PM Schedule/Time-based PM Run to Failure

www.impact-rlw.com

Establish Basis of Implementation • Begin with the end in mind, and the overall implementation constraints • Asset coverage – definition of system boundary • Asset Management Strategy • Cost • It’s easy to collect data – but how do you know you are looking in the right place? • Understand component relationships and system vulnerabilities through design and experience • Maintenance history • Legislated inspection criterion • Failure Modes, Effects, and Criticality Analysis (FMECA) • Reliability Centered Maintenance (RCM) Analysis • Physics-of-Failure modeling

www.impact-rlw.com

Monitoring Systems Enables Upstream Analysis Detect

Diagnostics and Prognostics

Monitor

Maintenance Reasoning

• Monitor: Acquire, process, and deliver Objective Quality Evidence (OQE) • Detection: Monitored parameter(s) has departed its normal operating envelope • Diagnosis: Identify, localize, and determine severity of an evolving (incipient fault through functional failure) condition • Prognosis: Reliably and accurately forecast remaining operational time to end of useful life, future condition, or risk to complete planned operations – “mission readiness” www.impact-rlw.com

Case Study – US Navy Shipyard Cranes • Customer has 28 portal cranes at 4 remote sites • No objective evidence of asset utilization • No automated workflow – pure schedule based maintenance. • Program Goals •

Provide ability to monitor shipyard capital assets, facilities and equipment in support of performing maintenance based on objective evidence of need -- Condition Based Maintenance (CBM) IAW OPNAVINST 4790.16a

• •

Develop, install and accredit secure wireless network Enable shipyard business processes and applications (e.g., IBM Maximo) Improve Asset Availability – Decrease Maintenance Costs

www.impact-rlw.com

System Key Characteristics • Function usage data collected for bridge and portal cranes at one Shipyard. • In this case, usage is the first assessment of condition.

• Introduce at-the-hook load monitoring technology. • Provide data on asset usage to EAM application • Complete Certification and Accreditation (data security) process to ensure integrity of wireless transmission. • Use Open Systems and a modular architecture to support future applications.

www.impact-rlw.com

Open Platform for Condition Monitoring

• • •

www.impact-rlw.com

Open systems approach permits easy installation. A modular approach permits hierarchical implementation. Embedded processing reduces bandwidth needs and increases overall system robustness.

SNAP2 - Technical Basis

SNAP2 Shipboard

 XML Interfaces [S2NAP® XML Schema]  8 Sensor Channels  Tachometer Input  2 Analog Output Channels  1 Relay Contact Output  2 EIA-232 Serial Ports. (Optional EIA 422/485)  Dual Processor Architecture  Wi-Fi (IEEE 802.11b) Wireless Network – FIPS 140-2  Mil-Qualified

Shipyard

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End-to-End Infrastructure

SNAP2

System

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SNAP2

System Enhancement – Direct Load Measurement • • • •

Customer cranes had no reliable load measurement systems. System installed on sister cranes operated for tandem lifts. Developed and implemented as risk mitigation for portal cranes. Developed with leading industry partner.

GL112 Hand Held Reference Load Display [lbs] Cell [lbs] 15,180 15,370 30,235 29,760 45,307 46,050 60,571 60,650 70,614 71,450

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Error ‐1.30% 1.60% ‐1.60% ‐0.10% ‐1.20%

Enhancement Extended to Portal Cranes • • •

At-the-hook load monitoring provides high accuracy load-moment indication on whip and main hoist. Safe Load Indication capability Data output compatible with enterprise monitoring system.

Modified main hook trunion www.impact-rlw.com

Portal Crane System Key Features • • • • • • • •

• •

Main Hook = 0.5% accuracy Whip Hoist = 0.1% accuracy Selectable Load Chart Single point zero from the cab Handheld displays for personnel on the ground Secure data transmission for storage in SQL database 6 month calculated battery life Design flexibility for future cranes depending on required accuracy Usage = How Much Adding Load = How Hard

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Web-based Data Display • Dashboard display of summary status and cumulative usage data. • Displays each lift profile as an individual event. • Data summarized in reports of usage over user-defined time intervals.

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Lifting and Handling Benefits Manage, Engineer, and Maintainer

Feature

Benefit

In-line measurement

Eliminates line rider induced rope wearout

High-accuracy

Eliminates dyno/excess gear

eMail Alerts

Faster incident/breakdown response

EAM Connectivity

OQE Generation to enable CBM Automatic work order generation

Expandability

Low-cost integration of additional monitoring (e.g. oil sensing)

Cab Display

Fast operator response – overload avoidance

Stored Data

Incident reconstruction/resolution, life analyses

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Implementation Lessons - IT System Integration • Remote monitoring systems must preserve data integrity • Bandwidth is expensive – embedded processing reduces data quantity • Introduction of Operational Technology (OT) vice Information Technology (IT) presents technical and administrative challenges • Certification/Accreditation of Applications • Integration with enterprise apps desirable from a security perspective

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Future Applications - SmartMon-Oil An Embedded Monitoring Sensor •

Multi-sensor fluid quality monitor • Broadband Impedance Spectroscopy, RH, Temperature measurements

•

Uses patented broadband measurement technique • Measure more fluid parameters => trend more fluid degradation modes • Much faster than traditional EIS measurements

•

Onboard processing • Smart sensor converts measurements to meaningful information • Impedance and feature calculations • Diagnostic and prognostic algorithms

• •

Small form factor / lightweight design Digital communications interfaces • •

CAN – J1939 RS-485/422 - Modbus

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Design Considerations – Integrating with the Enterprise •

Use of Open Standards • Open Systems Architecture – Condition Based Maintenance / Enterprise Asset Integration (OSA-CBM/EAI)

•

Enterprise Asset Management Integration • Data enables workflow automation • Faults/incipient failures can be routed to the right person at the right time • Enables Performance Based Logistics

•

Hierarchical Components • Modules arranged in a hierarchical relationship that mirrors the functional organization of the machine component, and the functional organization of the system • Component level processing permits straightforward interpretation of the interaction between components • Distributed processing increases system robustness

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Conclusions •

Begin with the end in mind – design and apply asset monitoring technologies to enable an overall strategy. The data is only useful if analyzed in context.

•

Early collaboration between engineering and IT to assist in the application of OT.

•

Components that employ local processing and can be applied in a hierarchical, open system anticipate future needs and evolving analysis capabilities and enterprise planning needs.

www.impact-rlw.com

Any Questions? Thank you. Aaron J. Spak Aaron.Spak@impact-tek.com

www.impact-rlw.com

Program part two Wednesday 13th April Operational Maintenance & Inspection continuous Chair: Stephen Werhle 13:00 A RFID inspection system the new Crosby Quic ‐ Check, inspection and identification system , Frédéric Crynen 13:45 Temporary lifting facilities for the BP Magnus crane replacement, Gordon Mccombie 14:30 Coffee / CraneExpo

Speaker

Speaker: Frédéric Crynen, Crosby Europe, UK Lecture: A RFID inspection system The new Crosby QUIC – CHECK, inspection and identification system Background: He has been working for Crosby Europe N.V. since January 2006. He is born in Antwerp, Belgium, on the 21st of June 1981 and graduated from Antwerp University in 2004 with a degree in Economic Sciences.

Crosby is a world leading manufacturer of lifting & rigging equipment with production units in the USA, Canada, Belgium, France, Holland and the UK.

Different products have type approval such as DNV, API, ABS,â&#x20AC;Ś

Crosby is an innovative company with different tools to support our distributors & end users. - Interactive website www.thecrosbygroup.com - Complete catalogue (including user & warning instructions, videos,â&#x20AC;Ś) - 2D-drawings - VerificationPro - Crosby Knowledge Center (online self-study) - Different calculators & configurators

- Apps for Iphone & Ipad - Training seminars - LEEA approved seminar - Heavy Lift seminar - Block Clinic

- Quic-Check RFID software

Quic-Check Radio Frequency Identification (RFID)

Crosby has developed an electronic inspection software that incorporates the technology of RFID, to provide a tool for our business partners that provides many benefits.

RFID and the identification of products to inspect

Types of RFID record keeping systems: PC Based Inspections are completed on handheld unit Handheld must be manually synchronized to user database Only data for single location viewable

Web Based Inspections are completed on handheld unit Handheld is synchronized to user database simultaneously Data can be viewed from anywhere with web access and a security code

The process

Crosby “RFID equiped” products:

Eliminator Chain Fittings

McKissick Blocks

Crosby Shackles 25t & larger

CrosbyIP Plate Clamps

Crosby Hoist Rings

Points to consider… – Do you conduct onsite inspections? – How many hours are spent throughout the entire inspection process? – How accurate are the inspection reports? – Are your inspection reports typed & formatted? – Can you currently pick up any product to inspect and quickly determine when it was last inspected, as well as the inspection status?

Different types of RFID – Active (long range, battery powered, finite life span) – Passive (no battery, powered on by reader, infinite life span) – Standards • Low, High, Ultra high frequency

Components of an RFID assisted electronic inspection system: 1. Tag or chips 2. Reader (pda & pen) 3. Software

The basics: RFID simply assiociates the “globally unique” number of the RFID tag with the unique serial number assigned to your product (shackle, chain sling, snatch block,…)

Benefits – – – – – – –

Accuracy of inspection reports Timelines of reports Inspection history Product tracking Improved employee efficiency In field validation of inspections Reduced liability

Benefits Accuracy of inspection reports Timelines of reports Inspection history Product tracking Improved employee efficiency In field validation of inspections Reduced liability

Eliminates handwritten information Eliminates need to re-type inspection reports No misread or incorrectly recorded tags

Benefits Accuracy of inspection reports Timelines of reports Inspection history Product tracking Improved employee efficiency In field validation of inspections Reduced liability

Less manual entry… means less proofreading…which more timely reports Report can be issued same day as inspection was conducted

Benefits Accuracy of inspection reports Timelines of reports Inspection history Product tracking Improved employee efficiency In field validation of inspections Reduced liability

“Cradle to grave” service history available Ability to view each inspection performed on the product since it was first placed into service

Benefits Accuracy of inspection reports Timelines of reports Inspection history Product tracking Improved employee efficiency In field validation of inspections Reduced liability

As a minimum, the location of the last inspection is recorded. Additional product information may be recorded and tracked Date of inspection Noted defects (if found) Applicable comments Status of the product after inspection

Benefits Accuracy of inspection reports Timelines of reports Inspection history Product tracking Improved employee efficiency In field validation of inspections Reduced liability

ď&#x192;&#x2DC;Reduces potential downtime associated with the inspection process by as much as 65%

Benefits Accuracy of inspection reports Timelines of reports Inspection history Product tracking Improved employee efficiency In field validation of inspections Reduced liability

Utilize reader for instant identification of critical or retired slings Should be able to read tag in the field to quickly to quickly determine if the product is within specification. Status of sling Last inspection date Date of next inspection

Benefits Accuracy of inspection reports Timelines of reports Inspection history Product tracking Improved employee efficiency In field validation of inspections Reduced liability

Inspection records are kept upto-date and maintained electronically. Provides a proper audit trail of a product’s safety history, including repairs, pull tests and visual inspections. Provides accurate, extremely detailed inspection reports in case of a safety audit or workplace incident.

RFID demo

1. Start software & discuss homepage 1. Contacts 2. Products 3. Inspections

2. Contacts 1. Distributor 2. End user (add new) 3. Manufacturer

3. Products 1. Product type 1. Existing products already in the system 2. Create new category + product

4. Create new product 5. Inspect products 6. Reporting

Speaker

Gordon Mccombie, Sparrows group, UK Lecture: Temporary lifting facilities for the BP Magnus crane replacement Background: Gordon McCombie is a well‐known figure within the oil and gas industry, having represented Sparrows’ wide range of products and services for over 26 years. Gordon has played an integral role in the growth and development of Sparrows since the early 80’s, responsible for expanding the machining services division and promoting lifting engineering and design services within the engineering, marine and drilling sectors.

Temporary Lifting Facilities. 16TH North Sea Offshore Cranes & Lifting Conference Life Extension Project â&#x20AC;&#x201C; 2010 / 11

Presented by: Gordon McCombie

BP Magnus

Introduction “BP Magnus Life Extension Project” – Survey – Crane upgrade or crane replacement – Opportunity for lifting operations improvement – The challenges – Methodology

Survey Survey objectives; – – – – – – – –

Define / identify all key plant locations Define key lift weights & description Confirm short/medium/long term lifts for each crane for life of field Platform management to specify all major projects over next 10 years Determine power requirements prime mover for new cranes (diesel / electric) Identify all lay down areas Confirm location of all existing blind lifts Confirm pedestal strength / overturning moment • Inspection reports • Any defects • Any limiting factors

Crane upgrade or crane replacement?

Analysis; 1. 2. 3.

Crane replacement (new cranes) Offshore upgrade of existing Stothert & Pitt cranes Onshore upgrade of existing Stothert & Pitt cranes

Replacement / Upgrade Justification • • • • • • • • • •

OEM recommended life HSE integrity inspections Single point failures (winches) Fatigue (all major components) Known boom defects Capacity –future coiled tubing lifts on platform Hoist speed – for boat lifts Pump spares obsolescence Motor spares obsolescence Increasing maintenance costs

Pros / Cons - Crane Replacement •

Pros ‐ Latest generation cranes

‐ Less maintenance down time ‐ Increased boom Length ‐ Increased capacity @ 35m (for coil tubing lifts ‐ Increased spares for ‘B’ crane

•

Cons – Greater initial cost – Long lead time – Possible boom rest & other modifications

Pros / Cons – Offshore Upgrade •

Pros – Cheapest option – Shortest overall project completion – Increased life of existing crane

•

Cons – Limited scale of upgrade – Extensive platform disruption • Crane downtime • Loss of lay down area • Loss of access to large portion of pipe deck

– Increased exposure to un‐ foreseen delays

Pros / Cons - Onshore Upgrade •

Pros

•

– Delivery of a more comprehensive overhaul/ upgrade compared with the offshore option i.e. • Chassis overhaul / upgrade • “A” frame overhaul / upgrade • Cranes fully tested prior to re – installation

– Minimised disruption to sea lifting cranes – Less platform disruption than offshore upgrade option

Cons – Higher upgrade cost compared with offshore upgrade option – Longest project timescale of all three options

Crane upgrade or crane replacement summary • Stothert &Pitt OS200 ‐Upgrade considerations – – – – – –

Obsolete systems / design features Single point failures Age Lifting performance limitations Increasing maintenance costs Upgrading work performed on or off the installation

• Kenz‐Figee B.V.DHC 70/3500 OS Ex. (Proposed replacements) – Pedestal height increased with installation of a new adaptor attached to existing pedestal flanges – EN13852‐1 standard / compliant – Increase in lifting performance – Good for remaining life of platform – Existing OEM support

Opportunity for lifting operations improvement

•

Improvements / benefits; – Elimination of obsolete systems & design features – Meets with EN13852‐1 standard – Physical increase in crane pedestal height – Elimination of blind lifting conditions – Improved visibility during deck & sea lifting operations – Improved/ increased lifting speeds – Overall safer deck & sea lifting operations

The challenges

•

Overcoming requirement for temporary crane access to service both “a”& “c” cranes without re assembling the elevated skid structure. – Design /supply R.M.D (Kwikform) support structure. Overcoming the inadequate strength of the existing pedestal flange connection. – OEM design / supply purpose built segmented clamps creating a retaining ring around pedestal. Overcoming machining existing flanges to a pre determined size. – Design & manufacture special purpose insitu machining equipment

Methodology Temporary Crane & elevated skid structure

Methodology Inventor modelling image “A” crane

Elevated skid track

Temporary crane

“C” crane

Methodology •

Inventor modelling image

Methodology •

RMD elevated towers

Methodology •

RMD elevated towers

Bridging member assembly

Temporary crane installation

Temporary crane installation / boom assembly

Temporary crane commissioning & skidding

Final assembly at position No 1

Hydraulic skidding to position No 2

Pedestal flange machining

New adaptor installation

Adaptor & pedestal flange clamp ring assembly

Fem analysis of flange joint

Assembled joint

Crane Installation Rotating machinery bed installed View of deck taken from drill derrick

Machinery house installation

Cab Installation

Winch Installation

New “C” crane assembled complete

Progress to second crane position

New â&#x20AC;&#x153;Câ&#x20AC;? crane installed at position 1.

Temporary crane skidded to position 2.

Project summary • • • • • • •

New / replacement cranes: EN13852‐1 standard compliant Methodology employing modularised B.E. Mk60 temporary crane Elevated RMD towers / skid track structure facilitated temporary crane skidding Increased crane height via new adaptor eliminated many operator lifting issues New adaptor / existing pedestal flange strengthened using segmented ring / clamps Overcome pedestal flange dimensional control issues by machining underside of flange insitu. Bp now decided to replace the third B” crane with a new machine during 2013

The Sparrows Family of Brands

Acknowledgments • •

Sparrows Group acknowledge with thanks to all BP Magnus on / offshore personnel who assisted / participated in this project. We also acknowledge with thanks the assistance & support received from Kenz / Figee B.V. and all our other contracting partners in the successful delivery of this project.

Thank you all for your attention

Program part three Wednesday 13th April Late afternoon session Chair: John Morrison Headline: Personnel Transfer and Evacuation 15:00 Mob‐boat handling with offshore cranes – combination of design parameter Tor Raknestangen 15:40 Training & competence in crane transfer operations; the importance of being prepared, David Brittan 16:15 Lifting persons with carriers suspended from offshore cranes application of European commission guidance document, Gunnar Matre 17:00 End of day 2 with closing remarks, questions and reflections

Speaker

Tor Raknestangen,National Oilwell Varco Norway AS, NO Lecture: MOB – Boat handling with offshore cranes Background: He joined NOV (formerly AS Stålprodukter) as a Project Engineer in 1997, he received his Bachelors in Telematics the same year. He has been working as a Project Manager since 1998, the projects spanning from new deliveries, large modifications and development projects. Since 2009 he has been working as Product responsible for lattice boom cranes for the European market.

Lifting and Handling Solutions

Launch and recovery of MOB boat with offshore cranes Selection of crane design parameters

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NOV - Company Overview Company at a Glance NOV

•Employees

40,000

•Market Capitalization $33.1B •Revenue 2009

$12.1B

•Countries represented: 50+ •# of facilities:

700+

•# of service personnel 1700+ •# of engineers

3500+

Lifting and Handling

•NYSE

Loading and unloading of supply vessels

Lifting and Handling

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MOB Training

Lifting and Handling

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Relevant standards Norwegian sector North sea o

EN 13852-1 Lifting and Handling

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Relevant standards Norwegian sector North sea o o

NMD 854 NMD 853 Lifting and Handling

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Relevant standards Norwegian sector North sea o

NORSOK S-001 Technical safety Lifting and Handling

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Relevant standards Norwegian sector North sea o

NORSOK R-002 (preliminary edition) Lifting and Handling

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Relevant standards Norwegian sector North sea o

NORSOK R-003 Lifting and Handling

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Relevant standards Norwegian sector North sea o

FEM 1.001 / EN 13001 Lifting and Handling

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Relevant standards Norwegian sector North sea o o

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Lifting and Handling

DNV ABS Lloyds Germanischer Lloyds

Prel. R002

API 2 C

DNV 2.22

ABS ( N)

ABS (API)

Reduced SWL

SWL 2

2 SWL 3

SWL 3

SWL 2

SWL 3

Increased Structural SF

Indir.

1,5

Indir.

Indir

Indir.

Increased Rope SF

Indir.

Indir. /1,5

Indir.

Soft sling / damper requirement

Yes

MOB dynamic limit

Yes

Control system barriers

Yes

Secondary means of rescue

Yes

Secondary brake requirement

Yes

10 m/s SW 2m

Yes

Operational limits (training) One company â&#x20AC;Ś unlimited solutions

10 m/s Yes, Both SW 2m for NLS and LS

Lifting and Handling

EN 13852

Example of a typical crane for fixed installation North Sea

Crane design parameters: 50 tonnes on 3 fall / 15 tonnes on 1 fall Approx 50 meter operational radius.  MOB weight ≤3 ton No impact  MOB weight >3 and ≤ 7,5 -10 ton, gradually impacting crane design.  MOB 10 ton+ will be governing for crane design/size 

Lifting and Handling

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Consistency ď Ž Ea standard / class rule is written to be used as a standalone

standard, and is deemed to give the right level of safety of its own.

have a deep knowledge within the standards to be able to get what you are after.

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Lifting and Handling

ď Ž Combining standards are off course possible, but it is imperative to

Lifting on a “rainy day” Lifting and Handling

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Conventional pennant Weight lower end of pennant vs MOB weight 35

Lifting and Handling

0 Boat weight

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2000

3000

4000

5000

6000

7000

8000

9000

10000

Summary  The offshore crane still is the best way to

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Lifting and Handling

launch and recover MOB boats and will continue to be.  When designing Cranes intended for MOB handling the main issue will be to balance the “Normal“ lifting requirement against the regulatory requirements for emergency preparedness.

MOB Rescue situation

Lifting and Handling

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Speaker

David Brittan, Reflex Marine Ltd, UK Lecture: Training & competence in crane transfer operations; The importance of being prepared! Background: David graduated in mechanical engineering from Sheffield University (1986) and holds an MBA from Cranfield Business School (1999). He began his career as a well engineer with BP and later pursued an international career with a number of operators. He has held a several senior positions, including head of Well Engineering at BG. David was appointed to the Board of Reflex Marine in 2008.

Training & competence in crane transfer operations

Reflex Marine

54 Countries

Years Leading the Way in Safer Access Solutions

Units Operating Across 5 Continents

500

Units

Million

Operating worldwide in Tropical to Arctic Conditions

Passenger Transfers Performed Each Year

Contents The changing role of the personnel carrier Levers to reducing transfer risk The competence of users and owners of SCE? Inspection and Maintenance schedules Training Options Servicing Centre competence Case history of mass transport by crane transfer Summary

THE ROLE OF CRANE TRANSFER CARRIERS

Personnel Carrier Roles – Work Rate Emergency

2 Transfers per week

Ad‐Hoc

10 Transfers per week

Complimentary Mass Transport

30 Transfers per week

50+ Transfers per week

Personnel Carrier Roles – Work Environment Arctic

‐40 Deg C

Standard

‐20 Deg C

Tropical

+40 Deg C

Personnel Carrier Opportunities Helicopter at operating limits – Temperature – Distance – Effective Pax transfer rate

Helicopter integrity concerns – Monopoly markets – Local standards

Limited Operating budgets – Economic evaluations on logistical support – Marine / Heliport support bases

Carriers are changing to meet these requirements

Changing Carriers – Changing Systems? Traditional rope baskets – Visual check & disposal strategy

Modern Personnel Carriers – Long field life – Suspension system maintenance – Replaceable parts

– Ensure “Carrier Integrity”

REDUCING TRANSFER RISK

Factors affecting crane transfers A large number of factors that affect the safe conduct of all marine personnel transfers, including :‐ Met‐ocean conditions Landing area Vessel station keeping capability and response to sea conditions Visibility and line of sight Crew skill and experience Human factors

Crane Transfer Risk reduction through... Good design – High safety factor, protected, single point failures

Good inspection – Right frequency, right quality

80% of all incidents have a root cause in

human factors

Preventative maintenance – Comprehensive manuals and procedures

Good materials – Original and replacement

Good people – Skills and experience – Competence

Good record keeping – Service records, parts used, reminders for inspection or test

Design  Central column load path

Single central load column – difficult to damage Design Safety Factor in excess of 10 Units Load Tested to 2* Maximum Gross Mass Sling Assembly load tested to 2* SWL

Design No Welding on Critical Load Path

Simpler low cost field inspection (no skilled weld inspector) Eliminates the risk of weld related fatigue induced cracking Critical components replaced by simple mechanical change out

I & M

Training & briefings

Risk awareness

Operational Integrity

Vessels, Cranes & Transfer equipment

Procedures

Top 10 issues with offshore lifting Top Ten Issues

Issue No.

Rank

Competence of crane operator

Competence of banksmen/slingers

Man riding using winches

Planning g of lifting operations

Analysis of lifting accidents

Static and dynamic crane rating

Hook snagging on the supply boat

Competence of maintenance staff

Supervision of lifting operations

Inadequate maintenance

Courtesy of International Regulators Forum 2004

COMPETENCY in PERSONNEL CARRIERS

Who needs to be Competent? Daily checks... performed by? – Vessel or platform Decks Crews / Foreman – Crane Operators

Formal Inspections... performed by? – Vessel or platform foremen ? – Crane Operators or Vessel captains – Independent lifting authority.

Examinations and Load tests... performed by? – Onsite maintenance crews

– Third party service providers (assurance/accreditation)

INSPECTION AND MAINTENANCE

Objectives of inspection & maintenance Return equipment to as new condition Highlight any damage from operations Establish design weaknesses Ensure no intrinsic hazards – i.e. dropped object Ensure it is safe to operate for the next period

Inspection categories Four TYPES of inspections – – – –

Check Inspection Examination Proof load test

Templates provided by RML Operators to develop or embed recommended inspection templates into their inspection management system (Maximo etc.)

Maintenance & inspection schedule

Recommended Inspection scheme Pre‐operation check – prior to every use Formal inspection – at least every 6 months (in accordance with LOLER) Examination (and test) – at least every 12 months But... more frequent with higher use – Current users range from <5 to over 5,000 transfers per year

Recommended Maintenance scheme Sling Assembly Maintenance – Sling assemblies are critical AND vulnerable – New Slings at least every 12 months, possibly changed EVERY 3 months

Critical Parts Maintenance – New Critical Parts AT LEAST every 36 months, normally every 12 months

Spare Parts Maintenance – As required according to inspection

Critical Parts & Kits

Typical Maintenance Parts

TRAINING OPTIONS

Personnel Carrier Training Model 1 day Advanced Familiarisation Course

Certified Trainer

½ Day Familiarisation Course

USERS

RML Trainer

1 ½ day Inspection and Maintenance Course

Certified I&M

EQUIPMENT

Training objectives “To equip with the theory and practical knowledge to effectively Use, Inspect and Maintain Personnel Transfer Equipment”. Content Classroom Content Desktop Exercises Practical Sessions Test and Evaluation

Available support material

User manuals (website download) Maintenance and Inspection Manuals Inspection templates (Word and Excel web downloads) Operational User Briefing video Crane Transfer Golden Rules video Reference Documentation

Maintenance Manuals Step by Step Guide (100 photo pages) Including: – Inspection Set up – Critical Parts change out – Sliding Sleeve Inspection – Spring Change Out – Feet replacement – Sling Inspection – Load Testing

InspectionÂ templates

Crane Transfer – The GOLDEN RULES 1. Understand your risks: Each operation is unique, individual risk assessments required

2. Be familiar with your conditions; Check prevailing weather and met‐ocean conditions

3. Know your vessels Station‐keeping and stability, availability of a large clear landing area

4. Know your cranes Limitations, Maintenance, Certification, location, lift height, emergency lowering, hoist speed

5. Know your transfer device Select equipment suitable for your operating envelope and risk levels

6. Be familiar with your crews Training and competence 7. Plan your lift Swing Factor, weather, collision, snagging 8. If in doubt – STOP Perform dry runs 9. Recognize complex operations Where appropriate seek expert advice

10.Emergency planning Integrate crane transfers into emergency planning and perform drills, confirm capabilities

SERVICING CENTRE COMPETENCE

Accredited Service Centres Quality of servicing on SCE is essential. Training of service centre maintenance personnel Now establishing a world‐wide Accredited Service Centre Program – Audit schedule of QMS – Assured training – Assured facilities – Customer and unit record tracking

Examples of good inspection reports

CASE HISTORY of MASS TRANSPORTATION BY CRANE TRANSFER

CASE HISTORY – FROG 9’s in BAKU

Frog 9 History 2007 – Frog 9 developed with Seacor Marine LLC 2008 – 2 Frog 9’s in Angola – 2 years service – 600 people per week – zero incidents

2009 – 7 Frog 9’s to Azerbaijan – – – –

Helicopter replacement strategy Risk based selection 1+ year service history 2 Fast crew vessels, large landing deck area

2011 – Frog 9’s to Nigeria, Trinidad and Sakhalin

Passenger Transfer Rates per hour (one way)

Transfer Times Analysis Transfer Rates (pax/hour)

120

100

69 60

53 35

29 20

FROG‐3

Rope Basket (Benchmark)

FROG‐6

FROG‐9

See appendix 1 for detailed calculations & assumptions

FROG‐9 (Dual Use)

TORO 4

Baku, Azerbaijan Helicopters not used since 2009 2 FAST crew vessels and 7 Frog 9’s mobilised in Dec 2009 57,000 transfers in first 12 months 60 pax per hour avg. 120 pax per trip No incidents Vessel transit time 3‐4 hrs Very minor sickness complaints

Very High Use Maintenance Schedule Rotational schedule – 2 operational, 2 ready for use ,2 in maintenance, 1 spare

3 monthly Service Interval – After circa 1,500 lifts – Formal inspection conducted – Sling Assembly replaced

6 monthly Service Interval – – – –

After circa 3,000 lifts Examination and critical parts replaced Load Test Sling Assembly replaced

Mass Transportation Preparations

Passenger handling at port Passenger induction video Luggage handling procedures Inspection and maintenance training Local spare parts

SUMMARY

Concluding Messages Transfer equipment is important – ensure it is well designed and suitable for the intended duty Ensure an appropriate inspection frequency – understand your usage rate (past and future) The competence requirements of personnel who use, check, operate and maintain such equipment are different. Crane transfer carriers need comprehensive I&M regimes, as part of SCE register. Training for users and I&M personnel can only enhance the transfer system safety. Accredited Service Centres for peace of mind on servicing quality.

LET’S STRIVE FOR SAFER TRANSFERS THANK YOU FOR YOUR ATTENTION

Speaker

Gunnar Matre, DNV, NO Lecture: Lifting persons with carriers suspended from offshore cranes Application of European commission guidance document

Background: Gunnar Matre (born 1970) joined DNV in 1996 and has worked in section Cranes & Machinery in Bergen the last 13 years. Currently Group Leader with service responsibility for verification services within the section.

Lifting persons with carriers suspended from offshore cranes Application of European commission guidance document Gunnar Matre 13 April 2011

What is a CARRIER? DEFINITON IN MACHINERY DIRECTIVE 2006/42/EC:

‘Carrier’ means a part of the machinery on or in which persons and/or goods are supported in order to be lifted.

Annex I Section 4.1.1 (g)

Carriers used with offshore cranes SUSPENDED WORK PLATFORM (”BASKET”)

Carriers used with offshore cranes PERSONNEL TRANSFER CARRIERS

Carriers used with offshore cranes RESCUE BOATS (”MOB” BOATS)

European Commission guidance document, Dec. 2009 Clarifies status of 2 categories of equipment: 1. Interchangeable equipment assembled with lifting machinery for the purpose of lifting persons  Subject to Directive 2006/42/EC

2. Equipment used for the purpose of lifting persons with machinery designed for goods  Not subject to Directive 2006/42/EC



First revision drafted in 2005 by Machinery Working Group, with ref. to 98/37/EC



Used as reference in the Guide to 2006/42/EC, comments to Annex IV item 17



http://ec.europa.eu/enterprise/sectors/mechanical/docu ments/guidance/machinery/index_en.htm

Cat. 1: Interchangeable equipment  Equipment (carriers) assembled with lifting machinery in order to modify its function for the purpose of lifting persons  '...is assembled with...' means that the equipment is fitted to the lifting machinery by the user so that the assembly functions as an integral whole.  Included in the scope of the Machinery Directive, and requires: - CE-marking - EC Declaration of Conformity - Notified Body involvement, e.g. EC Typeexamination (Annex IV machinery).

Cat. 2: Equipment used with machinery designed for lifting goods  Carriers intended to be lifted with lifting machinery designed for lifting goods only, e.g. - cranes - fork lift trucks

 Category based on Directive 2009/104/EC (”use of work equipment”)  Annex II, Section 3.1.2: ”PERSONS MAY BE LIFTED ONLY BY MEANS OF WORK EQUIPMENT AND ACCESSORIES PROVIDED FOR THAT PURPOSE”

 Exception: “(…) EXCEPTIONALLY, WORK EQUIPMENT WHICH IS NOT SPECIFICALLY DESIGNED FOR THE PURPOSE OF LIFTING PERSONS MAY BE USED FOR THAT PURPOSE, PROVIDED APROPRIATE ACTION HAS BEEN TAKEN TO ENSURE SAFETY IN ACCORDANCE WITH NATIONAL LEGISLATION AND/OR PRACTICE PROVIDING FOR APPROPRIATE SUPERVISION (…)”

 Purpose of guidance document to exclude equipment for exceptional use from the scope of the machinery directive  Also excluded from the Machinery Directive (2006/42/EC) by the directive itself, by 7th recital

Categories and CE-marking  Category 1 – Interchangeable equipment: - To be CE-marked - May be used for both planned operations and in exceptional circumstances

 Category 2 – Equipment used with machinery not designed for lifting persons: - Not to be CE-marked - CE-marking prohibited - May only be used in exceptional circumstances, in accordance with national legislation

Carriers used with offshore cranes â&#x20AC;&#x201C; WHAT CATEGORY? 1. Interchangeable equipment? OR 2. Equipment used with machinery designed for lifting goods (not persons)?

Cat. 2: Equipment used with machinery for lifting goods? Exeptional use?  Launching/recovery of rescue boat: - training of rescue crew is performed regularly - rescue operations are exceptional, but, nevertheless, PLANNED operations

 Access to work places with suspended work platform: - may be both PLANNED and UNPLANNED (exceptional) operations

 Personnel transfer: - REGULAR operation in connection with crew shifts/transfers - an alternative means of medical transport (e.g. injured personell), exceptional, but, nevertheless, a PLANNED operation - an alternative operation in case of weather conditions prohibiting helicopter transport

Crane designed for lifting goods only?  Offshore cranes in accordance with EN 13852-1 may be designed for lifting persons

Cat. 2: Carriers used with offshore cranes?  Operations may be both exceptional and planned/regular  Most offshore cranes are designed for lifting persons as well as goods  CE-marked carriers are desired Category 2 not appropriate for carriers suspended from offshore cranes

Cat. 1: Interchangeable equipment (IE)? CONCEPT:  Definition, 2006/42/EC, Article 2 (b): - ‘interchangeable equipment’ means a device which, after the putting into service of machinery or of a tractor, is assembled with that machinery or tractor by the operator himself in order to change its function or attribute a new function, in so far as this equipment is not a tool

 IE canges the function of, or attributes a new function to existing machinery  IE does not have to fit the strict definition of machinery  IE may be put on the marked separately, by another manufacturer  IE follows the same formal procedures for CE-marking, as machinery  Manufacturer of IE takes responsibility for the combination machinery + IE  User manual for IE must inform which machinery the IE can be assembled with  End user may assemble IE with machinery. Does not need to consider if the combination is complying with the machinery directive. Lifting persons with carriers suspended from offshore cranes 13 April 2011 © Det Norske Veritas AS. All rights reserved.

Cat. 1: Interchangeable equipment (IE)? REQUIREMENTS AND CONSTRAINTS IN GUIDANCE DOCUMENT:  IE ”assembled with” lifting machinery - requires a certain integration between the carrier and the lifting machinery - to what extent?

 ”Equipment placed on (…) the hook of a crane is not considered interchangeable equipment (…)” - technical constraint to carriers suspended from the hook of an offshore crane, based on a political decision - excludes carriers used with offshore cranes from the definition of IE

Guidance document – Problems  Does not address the need for CE-marking of carriers to be suspended from offshore cranes  Conflicts with harmonised standard for offshore cranes, EN 13852-1 -

Harmonised under 98/37/EC Currently under revision, expected to be harmonised with 2006/42/EC Contains technical requirements for lifting persons No requirements to the carrier, but the carrier is intended to be suspended from the hook

 Manufacturer of IE is responsible for the safety of the assembly of crane + carrier. - safety is depending on crane design - only the crane manufacturer is able to evaluate the safety of the assembly crane + carrier

Need for clarification ď&#x201A;§ May carriers suspended from the hook of an offshore crane be regarded as interchangeable equipement, when the offshore crane complies with EN 13852-1?

Alternative approach – Lifting accessories  Carriers suspended from offshore cranes = Lifting Accessories  Definition, 2006/42/EC Article 2 (d): - ‘lifting accessory’ means a component or equipment not attached to the lifting machinery, allowing the load to be held, which is placed between the machinery and the load or on the load itself, or which is intended to constitute an integral part of the load and which is independently placed on the market; slings and their components are also regarded as lifting accessories

 The term ”load” may be understood as both ”goods” and ”persons”, ref. definition of ”lifting operation”, 2006/42/EC, Annex I sec. 4.1.1.(a): - ‘Lifting operation’ means a movement of unit loads consisting of goods and/or persons necessitating, at a given moment, a change of level.

 A carrier suspended from the hook of an offshore crane will therefore in most cases fit the definition of ”lifting accessories”.

Lifting accessories – Annex IV machines?  Categories of machinery to which one of the procedures referred to in Article 12(3) and (4) must be applied  List of machinery categories which require involvement of a Notified Body when machinery is not manufactured in accordance with a harmonised standard.  The term ”machinery” in the heading of Annex IV must be understood as machinery both in the strict sense and in the broad sense. - Ref. Guide to application of Directive 2006/42/EC – 2nd Edition – June 2010, §33

 Item 17: Devices for the lifting of persons or of persons and goods (…)  The term “Devices” is universal, i.e. it can be: - machinery in the strict sense, e.g. a crane - lifting accessories - interchangeable equipment

 Annex IV includes lifting accessories for lifting persons.

Lifting Accessories – Problem GUIDANCE DOCUMENT, Category 2:  ”(…) Such equipment is not used to attach the load to the machinery: therefore it is not a lifting accessory (although such equipment may be attached to the machinery by means of a lifting accessory such as a sling). Such equipment is to be considered as a part of the load. It is thus not in the scope of the Machinery Directive and shall not bear the CE-marking in relation to that Directive (…)”

 May lead to the understanding that carriers suspended from offshore cranes are not lifting accessories.

To summarise HOW DO WE CATEGORISE CARRIERS SUSPENDED FROM OFFSHORE CRANES IN TERMS OF THE GUIDANCE DOCUMENT?

Categorisation according to guidance document INTERCHANGEABLE EQUIPMENT?

EQIUPMENT USED WITH MACHINERY FOR LIFTING GOODS ONLY?

YES/NO

LIFTING ACCESSORIES?

Application of user directive 2009/104/EC Annex II, 3.1.2 ?  Offshore cranes are already designed for lifting persons  Lifting persons with offshore cranes are NOT exceptional operations, but planned or regular operations  Application of national legislation does not necessarily give any further risk reduction compared to application of MD  Application of national legislation introduces a barrier to trade and impedes the freedom of movement of goods.

 Application of user directive not appropriate.

Offshore crane carriers – interchangeable equipment? BY DEFINITION, NO:  Suspending a carrier from the hook does not change the function or introduce any new function on the crane, the functions are already there. FROM MANUFACTURERS VIEW:  Manufacturer of carrier, takes responsibility for the assembled combination.  Requires in depth knowledge of the crane.  Crane types must be listed in the user manual and declaration of conformity for the carrier. BY POLITICAL DECISION, YES:  Only minor changes to the guidance document needed to define them as IE.